IIT Madras

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Kotak - IIT Madras Save Energy Mission (KISEM)

Indian Institute of Technology Madras


The subject plant is located in Guwahati district of Assam and falls under NIC Category-22209. This assessment was carried out by the IEAC Center, IIT Guwahati, during the course of the year 2023.

General Info

Principal Product

Thermoware, Plastics

Plant Area (Sq.ft)


No. of Employees


Production Hours


Annual Production

Annual Sales


Assessment Summary

Total Energy Costs(per year)


Total Recommended Investment(one time)


Total Recommended Savings(per year)


Energy Costs Calculation

Annual Usage




Unit Cost


Annual Cost


Total Energy Costs(per year)


Observations & Recommendations
DM - Demand Management
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Maximum Demand that has been reached in the previous year is 1149 kVA while the sanctioned demand is 2000 kVASurrender the excess demand of 600 kVA₹25,92,000
CPF - Capacitor & Power Factor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
In previous year, from the month November 2022 to April 2023, PF is below 0.97Improve the power factor above 0.97 to get rebate of 3% of total unit consumption42,005₹3,44,441₹50,0001.7
Only 128 kVAR connected in 500 kVAR APFC in old panel. Only Single phase sensing in APFC panelReplace the derated capacity of 300 kVAR and also install three phase sensing
PF correction is based on feedback from single phase onlyInstall three phase sensing to bring PF to unity.
TR - Transformer
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Already, there is an onload tap changer in the transformer. So the function of AVR is minimizedBypass the AVR from transformer line to MV Panel ACB71347₹5,85,045₹7,00,00014.4
Transformer current harmonics (16%) is higher than the IEEE Standard of 8%Install Harmonics filter to avoid distortion in harmonics
CR - Compressor
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
Overall Air leakage is high (39 cfm) in Low pressure compressors.Arrest all the identified air leakages51,450₹4,21,890₹50,0001.4
Low pressure Compressor's current pressure setting is very high (9.3 bar)Reduce the pressure setting to 6.5 - 7 bar1,51,900₹12,45,580
Overall Leakages in the High pressure compressor is very high. one compressor is running only for air leakagesArrest all the identified air leakages2,14,200₹17,56,440₹50,0000.3
CT - Cooling Tower
ObservationRecommendationUnit SavingsAnnual SavingsInvestmentROIStatus
In Cooling tower for Injection moulding section, nearly, 31.5 m3/hr of water is flowing through bypass from hot water tank to cold water tankVFD can be installed to minimize and balance the excess water flow.44,100₹3,61,620₹1,50,0005
In Cooling tower for ASB machine section, nearly, 29 m3/hr of water is flowing through bypass and there is not much deviation in the flow when the third cold water pump is turned offThird cold water pump can be completely turned OFF and VFD has to be installed so that the excess water flow can be balanced.1,26,000₹10,33,200₹1,50,0001.7